Ultrasonic Welding Horn Pressure Feedback for Stable Tab Joining
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Solution Overview
Problem
Existing ultrasonic welding systems struggle to maintain consistent welding pressure during the welding process, leading to suboptimal welding quality due to reliance on pressure values from sensors at the anvil, which are not effectively used for real-time control.
Innovation Solution
A welding pressure control system that feedback-controls the ascent and descent of the horn based on pressure values sensed during the welding process, using a sensing unit and control unit to maintain consistent pressure through real-time adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pressure sensor is provided at the lower side of the anvil to obtain pressure values, then pressure measurement is enabled, but the pressure control during welding remains ineffective
Solution Approach 1:
The system uses the pressure sensor to continuously monitor welding pressure and feeds this information back to the control unit, which automatically adjusts the horn's descent speed and position to maintain optimal pressure throughout the welding process, transforming the pressure sensor from a mere measurement device into an active control element
2Manufacturing precision
If horn pressure is increased to improve welding quality, then welding quality improves, but pressure consistency during welding deteriorates
Solution Approach 1:
The system dynamically adjusts the horn's descent speed and position based on real-time pressure feedback, transitioning from a static pressure application approach to a dynamic control approach that maintains optimal pressure consistency throughout the welding process
Solution Approach 2:
The control unit continuously monitors pressure via the sensor and automatically adjusts horn position and descent speed to maintain consistent pressure, using feedback control to prevent pressure fluctuations that would otherwise occur during the welding process
3Productivity
If real-time pressure monitoring and control is implemented, then welding efficiency is optimized, but system complexity increases
Solution Approach 1:
The control unit performs multiple functions: it controls the elevating unit's operation, processes pressure sensor signals, adjusts horn descent speed, and maintains pressure consistency, thereby managing system complexity through a multi-functional control system rather than multiple separate components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system optimizes welding efficiency by maintaining consistent pressure on the welding subjects, reducing defects like electrode tab folding, and allows for real-time monitoring and adjustment of pressure values.
Implementation Method 1
The ultrasonic welding is a method of performing welding in such a manner that vibrational energy is selectively applied to a horn according to a control signal of a computer to allow the horn to be in contact with and press welding subjects
Implementation Method 2
frictional heat is generated through ultrasonic vibrations
Data Source
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AI summary
The present invention relates to a welding pressure control system, a welding pressure control method using the same, and a welding subject thickness measuring method using the same, and more particularly, to a welding pressure control system, which controls welding pressure via feedback control of ascent and descent of a horn on the basis of a pressure value sensed according to the ascent and the descent of the horn, and a welding pressure control method and welding subject thickness measuring method using the welding pressure control system. The present invention provides a welding pressure control system characterized by including: an anvil on which a welding subject is supported; a horn that is provided to face the anvil and presses the welding subject; an elevating unit that supports the horn to be ascendable and descendable; a sensing unit that senses a pressure value varying depending on the ascent and the descent of the horn; and a control unit that controls driving of the elevating unit on the basis of the pressure value obtained from the sensing unit, wherein the elevating unit includes a motor, a screw that receives driving power from a rotary axis of the motor and rotates, a vertically movable part that is coupled to the screw and moves vertically